3D printed bespoke orthotics

A revolutionary process that builds three-dimensional objects from digital files, 3D printing was originally developed for rapid prototyping in industrial design. By applying this cutting-edge technology to orthotics, the London Orthotic Consultancy (LOC) is transforming the way custom orthotic devices are designed and manufactured, offering unparalleled precision, comfort, and functionality for patients.

Unlike traditional manufacturing methods, 3D printing constructs orthotic devices layer by layer, allowing for intricate and highly customisable designs that were previously impossible to achieve. This approach enhances treatment outcomes by enabling precise control over the thickness, flexibility, and pressure distribution of each orthosis, ensuring a tailored therapeutic impact.

Innovations in 3D printed orthotics

New 3D printing technology has allowed us to innovate many of our existing orthotic products. The LOCband Lite cranial remoulding helmet for babies with flat head syndrome is entirely 3D printed. This has allowed us to design a helmet that is much lighter and easier and more comfortable for babies to wear.

We can design and print entirely custom 3D printed wrist supports as well as 3D-printed clips for our pectus carinatum brace and rib flaring brace.

Benefits of 3D printed orthotics

Having our own in-house manufacturing 3D printer offers several benefits to patients:

• Faster production and adjustments: 3D printing can streamline several aspects of the manufacturing process, allowing quicker turnaround times and easier modifications when required.
• Eco-friendly and sustainable: Unlike traditional orthotic manufacturing methods, like thermoplastic draping, 3D printing minimises material waste by using only the necessary amount needed for each device.

LOC’s in-house 3D printing capabilities

At LOC, we are pioneering the use of additive manufacturing in orthotic design. Our first in-house Markforged Mark II printer allows us to integrate high-performance materials into our production process, significantly enhancing both design flexibility and manufacturing efficiency.

This technology not only improves the quality of our orthotic devices but also aids our team by producing jigs, fixtures, and assessment devices for precise fittings and adjustments.

The LOCband Lite: a breakthrough in cranial remoulding helmets

One of our most exciting developments is the LOCband-Lite, an innovative cranial helmet designed using HP’s Multijet Fusion (MJF) technology. This 3D-printed helmet is a significant advancement in cranial remoulding therapy, featuring:

• A lightweight structure: The LOCband-Lite is thinner and lighter, reducing strain on the baby’s neck.
• Enhanced ventilation: Vented meshes allow for superior heat dissipation, improving comfort.
• State-of-the-art design benefits: Precision engineering ensures optimal fit and effectiveness for cranial treatment.

This breakthrough design offers tangible benefits for babies who need helmet therapy treatment, ensuring they receive treatment that is both effective and comfortable.

The future of 3D printing at LOC

At LOC, we are continuously exploring new applications of 3D printing in orthotics. With state-of-the-art equipment and a dedicated design team, we are committed to pushing the boundaries of what is possible in patient care. By integrating additive manufacturing into our practice, we are setting new standards for custom orthotic solutions that prioritise patient comfort, function, and long-term health outcomes.

For more information on our 3D-printed cranial helmets and other innovations, please contact us.